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10

ARC 800 Order No. BA 93-10-0702A   Issue 01.03.08

1.1

Guide to this Operating Manual

This operating manual provides you with the following information

"Delivery"

in Chapter 2

"Starting-up"

in Chapter 3

"Functional Principle"

in Chapter 4

"Stud Welding Process"

in Chapter 5

"Switching off the Power Unit"

in Chapter 6

"Care and Maintenance"

in Chapter 7

Technical Data and much more

in Appendix

THREAT TO LIFE and risk of serious health and material damage in

case of improper use of the power unit. Observe all notes in this

operating manual.

Note for qualified operators (see chapter 1).

All instructions contained in this manual must also be observed

by qualified operators.

The welding process and the sequence of procedures to carry

out a weld are described in chapter 5.

Summary of Contents for 93-10-0702A

Page 1: ...ARC 800 Power Unit 93 10 0702A Operating Manual...

Page 2: ...trasse 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail po hbs info com Web www hbs info com Copyright The information contained herein may not be copied reproduced adapted m...

Page 3: ...of malfunction In case of accident inform a physician and the responsible o cial body THREATTOLIFE Persons tted with a pace maker mu not operate the ud welding machine MAGNETICFIELDS During ud welding...

Page 4: ...e more copies please provide the order number li ed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreate care Althoughwedidourvery be tocorrectlyupdateanyinformationuptot...

Page 5: ...to the Power Unit 18 3 4 Ground Connection 19 3 5 Shielding Gas Connection 20 3 6 Change Working Place 20 4 Function 21 4 1 Components of the Power Unit 21 4 1 1 Power Unit 21 4 1 2 Control Unit 21 4...

Page 6: ...ending Test 35 5 8 3 Arc Blow E ect 37 5 9 Malfunctions and Corrective Actions 38 5 10 Welding Elements 39 6 Switching o the Power Unit 42 6 1 Temporary Switching off 42 6 2 Disposal 42 7 Care and Mai...

Page 7: ...0 Order No BA 93 10 0702A Issue 01 03 08 Glossary 64 Regulations and Standards 65 Further In ructions 67 Guarantee Clauses 68 EU Statement of Conformity 69 Con rmation 70 Feedback 71 Service Support 7...

Page 8: ...viii ARC 800 Order No BA 93 10 0702A Issue 01 03 08...

Page 9: ...epowerunit Strictly observe the safety instructions Before starting up the power unit let the operator sign the confirmation that he shehasreadandfullyunderstoodtheoperatingmanual seeappendix Donotcom...

Page 10: ...fthePowerUnit inChapter6 CareandMaintenance inChapter7 TechnicalDataandmuchmore inAppendix THREAT TO LIFE and risk of serious health and material damage in case of improper use of the power unit Obser...

Page 11: ...anual mean Threat to life or risk of personal injury Risk of material damage Ban for persons tted with a pace maker Warning of dangerous electrical voltage Warning of electromagnetic elds Wear protect...

Page 12: ...runitisintendedtoweldweldingelementsaccordingtoactualstandards see chapter 5 and appendix Any other use is regarded as not used as directed The manufacturerisnotliablefordamagesresultingfromthestudwel...

Page 13: ...ofthepowerunitcanonlybecheckedbeforestarting upbyvisual inspection visibledamage Thefollowingitemsaretobeobservedifthepowerunitisnottobeputintooperation immediatelyafterdelivery The power unit must be...

Page 14: ...y visible Type plate The type plate containsthe followingdata Manufacturer Type OrderNo SerialNo Primaryvoltage Fuse Powerconsumption Cooling class Protection class Date Safety symbols Replace illegib...

Page 15: ...No BA 93 10 0702A Issue 01 03 08 15 2 Delivery Thebasicequipmentofyourpowerunitcontainsthefollowingcomponents No of pieces Part Type Order No 1 Powerunit ARC800 93 10 0702A 1 Operatingmanual ARC800 B...

Page 16: ...articles or liquids Before you start welding remove any combustible articles or liquids in vicinity of theworkplace Make sure that a fire extinguisher is within reach Never weld in rooms exposed to r...

Page 17: ...rt any colleagues who are occupied in the vicinity of the welder Wear your personal protective equipment according to actual andards see appendix 3 2 Connecting the Power Unit to the Primary Power Sup...

Page 18: ...that they are properly locked In case of loose connection heat may build up in the plug and may de roy the entire plug connection Plug the control cable in the connector of the power unit Twist the r...

Page 19: ...ons regularly to ensure that they are properly locked In case of loose connection heat may build up in the plug and may de roy the entire plug connection Removeanyrust paint orcontaminantsfromtheworkp...

Page 20: ...low meter of the shielding gas bottle to 8 16 liters min Minimum ow rate for ud welding with shielded gas is 8 l min Agasmixtureof82 Argon Ar and18 carbondioxide CO 2 ismainlyusedforstud welding 3 6 C...

Page 21: ...wer unit consists of the main assemblies 1 Solid State Relais 2 Transformer 3 Rectifier 4 Controlunit Mains alternating current is transformed in the transformer 2 and converted in the rectifier 3 4 1...

Page 22: ...22 ARC 800 Order No BA 93 10 0702A Issue 01 03 08 4 2 Keyboard and Display Stand bydisplaygreen Readyforwelding Stand bydisplayred Locked How to use displays and keys is described in section 5 6...

Page 23: ...l shock and arc During the actual ud welding process do not touch the welding elements chuck or retaining nut nor any electrically conductive parts in their vicinity These are all electrically life St...

Page 24: ...ards see appendix non combu ibleclothes ear protection to current andards see appendix a protective apron over your clothes a protective headgear when welding overhead Before arting to weld remove all...

Page 25: ...d spatters a ash and a loud bang 90 dB A Alert any colleagues who are occupied in the vicinity of the welder Wear your personal protective equipment according to actual andards see appendix MAGNETIC F...

Page 26: ...ee appendix Drawn Arc Stud Welding The HBS stud welding unit operates by process of arc stud welding with drawn arc ignition accordingtothecurrentstandards seeappendix Thestandardsassignthis method of...

Page 27: ...sed on the use of welding elements which correspond with current standards seeappendix Variations on Drawn Arc Stud Welding Item Drawn arc stud welding with ceramic ferrule ring Drawn arc stud welding...

Page 28: ...heweldpool Standardweldingelementsandceramicferrulesaredescribedinseveralstandards see appendix When using concrete anchors or shear connectors the front area can be plane constructed with a small pre...

Page 29: ...dershieldinggas With shielding gas you should only weld in position PA verti cal because due to gravity the shielding gas cannot prevent ow of the molten metal 5 2 3 Short Cycle Drawn Arc Stud Welding...

Page 30: ...at seeoperatingmanualofaccordingwelding gun Beforewelding makesurethatthebellowsarecheckedfordamageandproper seat 5 4 High rength Welds Thefollowingmustberemovedbothfromtheweldzoneandthegroundclamp co...

Page 31: ...ed M4 5 32 5 10 or 3 16 50 M5 3 16 not normed M5 3 16 6 1 4 75 M6 1 4 5 4 0 21 60 M6 1 4 7 0 28 100 M8 5 16 7 19 0 28 100 M8 5 16 9 0 35 170 M10 3 8 9 0 35 165 M10 3 8 11 0 43 250 Designation PD MD De...

Page 32: ...oltage The digital display shows the adjusted welding time There is a luminous indication LED to the left of the display Green on powerunitisreadyforwelding Red on power unit is locked after welding u...

Page 33: ...the gas pre flow time with the two arrow keys longer shorter 01 corresponds to 100 ms 10 to 1 s adjustment range 0 to 2 s You return to the display of welding time by another simultaneous press on th...

Page 34: ...firmly still and straight take care that you do not touch any metallic part of the welding gun press the triggerbuttonof theweldinggun This initiates the welding process The welding process can only b...

Page 35: ...f the ceramic ring w elding element too long Welding energy too high Ceramic ring not centered correctly Decrease current and or time Check centering Weakly developed uneven w eld collar w ith mat sur...

Page 36: ...elding unit checkwhetherthesurfaceofweldingelementandbasematerialarecleanand electrically conductive must be free from scale oil paint oxide layers grindoffhardenedworkpiecesurfaces e g rollhardening...

Page 37: ...fthearc Itcausesasingle sided melting of the stud material increased pore formation and undercuts in the weldingarea The arc blow effect is proportional to the current and can be influenced by symmetr...

Page 38: ...ble for electrical flow w ith triggered start button Replace w elding gun trigger button Qualified personnel Control cable broken Check control cable for electrical flow Replace control cable Qualifie...

Page 39: ...ding gas M6 15 40 mm 83 50 006 83 51 006 M8 15 50 mm 83 50 008 83 51 008 M10 20 55 mm 83 50 010 83 51 010 M12 25 60 mm 83 50 012 83 51 012 M16 30 65 mm 83 50 016 83 51 016 Chuck Materials S235 St37 3k...

Page 40: ...51 010 M12 20 50 mm 83 50 012 83 51 012 M16 20 50 mm 83 50 016 Chuck Materials S235 St37 3k 4 8 1 4301 1 4303 Head stud SD Diameter Length Chuck ceramic 1 4 6 50 100 mm 83 53 006 3 8 10 50 175 mm 83 5...

Page 41: ...30 222 Materials S235 St37 3k 4 8 1 4301 1 4303 Threaded stud FD with flange Diameter Length Chuck M3 on request 82 50 003 M4 on request 82 50 004 M5 on request 82 50 005 M6 on request 82 50 006 M8 on...

Page 42: ...rarilyorcompletely 6 1 Temporary Switching o Switch off the power unit Unplugthecontrolcableandtheweldingcablefromthepowerunit Protectthepowerunitagainstingressoffluidsandforeignbodies 6 2 Disposal If...

Page 43: ...plug Do not wear a wri watch or any electrically conductive jewellery 7 2 Regular Maintenance Operations Clean the inner components of the power unit periodically of du Use a dry washcloth or a brush...

Page 44: ...are su ciently quali ed in repairing electrical equipment Remove the 10 screws of the casing 5 at each side Carefullyremovethecoveranddisconnectthegroundcableontheinsideofthe cover Nowpulloffthecover...

Page 45: ...terial Mild steel stainless steel Weldingrate 7 to 17 studs min depending on application and stud dia Weldingcurrent 800A Welding time 5 to 1 000 msec Primarypower 400 V 3 phases 50 60 Hz 35 AT altern...

Page 46: ...4 2 80 10 249 Flat connection 15 1 88 11 387 Support unit complete 16 2 80 90 140 Spring washer 8 mm 17 2 80 90 141 Nut M8 20 1 88 11 268A Front plate complete 21 1 80 10 159 Cap 22 2 80 10 115 Cap 25...

Page 47: ...ARC 800 Order No BA 93 10 0702A Issue 01 03 08 47 Power unit ARC 800 93 10 0702A...

Page 48: ...lcablesleeve 34 4 80 90 179 Screw M4 x 12 35 1 80 50 480 Primary switch 40 2 88 11 283 Distance sleeve 6 5 x 9 45 1 80 80 497 P C boardARCprocessor Observeprogramversion 50 2 80 11 023 Distance stud 5...

Page 49: ...ARC 800 Order No BA 93 10 0702A Issue 01 03 08 49 Front plate complete ARC 800 88 11 268A...

Page 50: ...2 80 10 785 Adhesiveclip 40 1 80 11 643 Cablemountingpluggable 45 1 80 50 927 Mainsinterferencefilter 46 14 80 90 191 Screw M4 x 8 49 6 80 90 147 Springwasher6mm 50 1 88 11 263 Mountingplate 51 6 80 9...

Page 51: ...Resistor L 97 2 80 90 202 Washer 5 mm 98 2 80 90 127 Screw M5 x 8 100 1 88 11 252 Transformer400V 105 1 80 80 491 P C boardARCtransformer 110 2 80 55 021 Solid State Relay 112 2 80 70 346 Varistor 11...

Page 52: ...ARC 800 88 11 259A Pos Quantity OrderNo Description 5 1 88 16 456 Rearwall 10 1 80 10 0960 ZEVB Screwing 15 1 80 11 567 Lock nut 30 1 80 50 049 Fan 31 4 80 90 108 Screw M4 x 12 32 4 80 90 121 Springw...

Page 53: ...ARC 800 Order No BA 93 10 0702A Issue 01 03 08 53 Rear wall complete ARC 800 88 11 259A...

Page 54: ...173 Screw M4 x 10 12 4 80 90 164 Washer 4 mm 15 1 88 11 258 Resis torsupport 16 2 80 90 152 Screw M5 x 10 17 2 80 90 128 Springwasher5mm 18 2 80 90 202 Washer 5 mm 20 1 80 57 041 Resistor 25 1 88 11 2...

Page 55: ...ARC 800 Order No BA 93 10 0702A Issue 01 03 08 55 Bottom unit complete ARC 800 88 11 386...

Page 56: ...gas module ARC 800 93 50 020 Pos Quantity OrderNo Description 100 1 80 10 145 Connectorfemale 110 1 80 10 024 Nipple 115 1 80 10 139 Connectormale 120 1 80 10 146A Solenoidvalve 122 2 88 11 839 Connec...

Page 57: ...ARC 800 Order No BA 93 10 0702A Issue 01 03 08 57 Shielding gas module ARC 800 93 50 020...

Page 58: ...an Before arting any repair or maintenance operation always switch the power unit o and disconnect the primary plug Do not wear a wri watch or any electrically conductive jewellery To change the elect...

Page 59: ...ers Replacetheelectronicboard Forre assembly proceedinreversedsequence Replacement of the electronic board 80 80 497 Seechangingtheelectronicboard80 80 490 Inaddition youmustremovethe two spacers Repl...

Page 60: ...60 ARC 800 Order No BA 93 10 0702A Issue 01 03 08 Main board 80 80 497 Please observe the program version...

Page 61: ...ARC 800 Order No BA 93 10 0702A Issue 01 03 08 61 Transformer board 80 80 491...

Page 62: ...62 ARC 800 Order No BA 93 10 0702A Issue 01 03 08 8 3 Electrical Circuit Diagram...

Page 63: ...93 10 0702A Issue 01 03 08 63 8 4 Environmentally Admissible Disposal Afterrepairofthepowerunit disposereplacedpartsinanenvironmentally admissibleway Usedmaterials Steel Nonferrousmetals brass copper...

Page 64: ...dfeeder Device for the automatic stud feeding of welding ele ments Studweldingunit Powerunitinclusiveweldinggun Thyristor Electronic component contactless switch which will let the current only pass t...

Page 65: ...rials DVS0901 Studweldingmethodformetals Survey DVS0902 Arc stud welding DVS0903 Capacitordischargeweldingwithtipignition DVS0904 Tips Arc stud welding DVS2927 ResistorprojectionweldingandArcweldingof...

Page 66: ...t Part 10 Requirements Personalsafetyandaccidentprevention DINENISO20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DINEN166 Personaleye protection Specifications...

Page 67: ...7 3 8 2 2 3 1 3 2 4 5 M8 8 0 15 0 4 9 9 5 4 0 7 5 6 0 11 0 M10 13 0 30 0 7 8 19 0 M12 19 0 53 0 12 0 33 0 M16 35 0 135 0 22 0 82 0 Steel 4 8 1 0 18 Rp0 2 340 N mm 2 1 4301 03 A2 50 0 18 Rp0 2 210 N mm...

Page 68: ...ancelledifrepairoperationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the ud welding unit as well as unauthorized alteration of the ud welding unit are prohibited and re...

Page 69: ...the equipment without prior written approval by HBS Description of equipment Power Unit 0 0 8 C R A e p y T Order No 93 10 0702A Serial No Applicable EG guidelines and corresponding andards Low voltag...

Page 70: ...______________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ _...

Page 71: ..._________________ 85221 Dachau Germany __________________________ Po fach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________...

Page 72: ...72 ARC 800 Order No BA 93 10 0702A Issue 01 03 08 Service Support...

Page 73: ...ivecables 30 delivery 10 15 display 22 disposal 42 disposal environmentallyadmissible 63 distancedevice 34 drawn arcstudwelding variations 27 DVSregulations 33 E earprotection 9 24 electrical circuit...

Page 74: ...restress at installation 31 67 primarypowersupply 17 production 9 programversion 48 59 60 protectiveapron 24 protectiveequipment 17 25 protectiveequipment personal 9 protectivegloves 24 protectivegogg...

Page 75: ...packaging storage 13 type plate 14 17 U unauthorizeduse 9 V vapors toxic 16 visualinspection 35 W weld checking the quality of the 34 weldingelements 12 31 39 64 weldingelements lotof 31 weldinggun 1...

Page 76: ...76 ARC 800 Order No BA 93 10 0702A Issue 01 03 08...

Page 77: ......

Page 78: ...HBS Bolzenschweiss Sy eme GmbH Co KG Felix Wankel Strasse 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail po hbs info com www hbs info com...

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